Wearable robotic device

ABSTRACT

A self-aligning, self-drawing coupler for coupling body assemblies together improves usability of a wearable robotic device. A self-contained removable actuator cassette improves the ease of manufacture and of replacing parts in the field. A tensioning retention system designed for one handed operation makes donning and doffing a wearable robotic device easier. A two-stage attachment system increases the range of sizes a wearable robotic device will fit. A removable, integrated ankle-foot orthotic system makes donning and doffing a wearable robotic device easier. An infinitely adjustable, integrated ankle-foot orthotic system increases the range of sizes a wearable robotic device will fit. A manually-removable hip-wing attachment system makes field changes easier, and protecting such a system from inadvertent disengagement during operation increases safety.

RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 15/119,403filed Aug. 17, 2016 which is a national phase of International PatentApplication Serial No. PCT/US2015/023624 filed Mar. 31, 2015, whichclaims the benefit of U.S. Provisional Application No. 61/973,129 filedMar. 31, 2014, which is hereby incorporated herein by reference.

FIELD OF INVENTION

The present invention relates generally to wearable robotic devices, andmore particularly to improvements in operability to powered lower limborthoses.

BACKGROUND

There are currently about 262,000 spinal cord injured (SCI) individualsin the United States, with roughly 12,000 new injuries sustained eachyear at an average age of injury of 40.2 years. Of these, approximately44% (5300 cases per year) result in paraplegia. One of the mostsignificant impairments resulting from paraplegia is the loss ofmobility, particularly given the relatively young age at which suchinjuries occur. Surveys of users with paraplegia indicate that mobilityconcerns are among the most prevalent, and that chief among mobilitydesires is the ability to walk and stand. In addition to impairedmobility, the inability to stand and walk entails severe physiologicaleffects, including muscular atrophy, loss of bone mineral content,frequent skin breakdown problems, increased incidence of urinary tractinfection, muscle spasticity, impaired lymphatic and vascularcirculation, impaired digestive operation, and reduced respiratory andcardiovascular capacities.

In an effort to restore some degree of legged mobility to individualswith paraplegia, several lower limb orthoses have been developed. Thesimplest form of passive orthotics are long-leg braces that incorporatea pair of ankle-foot orthoses (AFOs) to provide support at the ankles,which are coupled with leg braces that lock the knee joints in fullextension. The hips are typically stabilized by the tension in theligaments and musculature on the anterior aspect of the pelvis. Sincealmost all energy for movement is provided by the upper body, these(passive) orthoses require considerable upper body strength and a highlevel of physical exertion, and provide very slow walking speeds. Thehip guidance orthosis (HGO), which is a variation on long-leg braces,incorporates hip joints that rigidly resist hip adduction and abduction,and rigid shoe plates that provide increased center of gravity elevationat toe-off, thus enabling a greater degree of forward progression perstride. Another variation on the long-leg orthosis, the reciprocatinggait orthosis (RGO), incorporates a kinematic constraint that links hipflexion of one leg with hip extension of the other, typically by meansof a push-pull cable assembly. As with other passive orthoses, the userleans forward against the stability aid while un weighting the swing legand utilizing gravity to provide hip extension of the stance leg. Sincemotion of the hip joints is reciprocally coupled through thereciprocating mechanism, the gravity-induced hip extension also providescontralateral hip flexion (of the swing leg), such that the stridelength of gait is increased. One variation on the RGO incorporates ahydraulic-circuit-based variable coupling between the left and right hipjoints. Experiments with this variation indicate improved hip kinematicswith the modulated hydraulic coupling.

In order to decrease the high level of exertion associated with passiveorthoses, the use of powered orthoses has been previously investigated,which incorporate actuators and an associated power supply to assistwith locomotion. These orthoses have been shown to increase gait speedand decrease compensatory motions, relative to walking without poweredassistance, however, the development of these orthoses is still in itsinfancy

SUMMARY OF INVENTION

A self-aligning, self-drawing coupler for coupling body assembliestogether improves usability of a wearable robotic device. Aself-contained removable actuator cassette improves the ease ofmanufacture and of replacing parts in the field. A tensioning retentionsystem designed for one handed operation makes donning and doffing awearable robotic device easier. A two-stage attachment system increasesthe range of sizes a wearable robotic device will fit. A removable,integrated ankle-foot orthotic system makes donning and doffing awearable robotic device easier. An infinitely adjustable, integratedankle-foot orthotic system increases the range of sizes a wearablerobotic device will fit. A manually-removable hip-wing attachment systemmakes field changes easier, and protecting such a system frominadvertent disengagement during operation increases safety.

According to one aspect of the invention, a wearable robotic deviceincludes a thigh assembly for attachment to a thigh of a user having afirst portion of a self-aligning, self-drawing coupler; a hip assemblyfor attachment to a hip region of the user having a second portion ofthe self-aligning, self-drawing coupler; and a latch configured to drawthe first portion of the self-aligning, self-drawing coupler to alatched position relative to the second portion of the self-aligning,self-drawing coupler.

Optionally, the first portion of the self-aligning, self-drawing couplerincludes a tapered male portion receivable in a complimentary taperedfemale portion of the second portion of the self-aligning, self drawingcoupler.

Optionally, a length of the tapered male portion is longer than a widestwidth portion.

Optionally, the tapered male portion includes a taper angle of between 1and 10 degrees.

Optionally, latch includes a manually operable lever.

Optionally, the first portion of the self-aligning, self-drawing couplerincludes a male portion receivable in a complimentary female portion ofthe second portion of the self-aligning, self-drawing coupler, one ofthe male or female portions including a friction-reducing surface.

Optionally, the friction-reducing surface is a Teflon coating.

Optionally, the thigh assembly extends downward along a longitudinalthigh axis from the first portion of the self-aligning, self-drawingcoupler.

Optionally, the thigh assembly includes a motive device.

Optionally, the hip assembly extends upward and laterally away from thesecond portion of the self-aligning, self-drawing coupler, and partiallycircumscribes a vertical body axis.

Optionally, the hip assembly extends laterally away from the secondportion of the self-aligning, self-drawing coupler, and includes asecond portion of a second self-aligning, self-drawing coupler.

Optionally, the wearable robotic device includes a second thigh assemblyfor attachment of a second thigh of the user and including a firstportion of a second self-aligning, self-drawing coupler.

Optionally, the thigh assembly is rotatable with respect to the hipassembly when the thigh assembly is coupled to the hip assembly by theself-aligning, self-drawing coupler.

Optionally, the wearable robotic device includes a power source and amotive device powered by the power source and configured to rotate atleast a portion of the thigh assembly relative to at least a portion ofthe hip assembly.

Optionally, the thigh assembly includes the motive device.

Optionally, the second portion of the self-aligning, self-drawingcoupler includes a linkage device configured to transmit motion from aninput lever to a latch element.

Optionally, the linkage device includes an input link, a floating link,an output link, and a ground link.

Optionally, the linkage device includes a lever as the input link.

Optionally, the linkage device includes a resilient latch elementcoupled at a first end to the output link.

Optionally, the resilient latch element has a second end slidablycaptured in a guideway for controlling motion of the latch elementduring operation.

Optionally, the guideway includes a generally straight draw portionaligned with the female portion of the coupler, and an engagementportion extending laterally away from the draw portion for guiding thelatch element into and out of engagement with a corresponding latchelement of the second portion of the coupler.

Optionally, the resilient latch element provides a biasing force in thelinkage mechanism for locking the linkage mechanism in an over-centerconfiguration.

Optionally, the over-center position is a locked open position.

Optionally, the over-center position is a locked closed position.

According to another aspect, a wearable robotic device includes a firstbody assembly having a first portion of a self-aligning, self-drawingcoupler; a second body assembly having a second portion of theself-aligning, self-drawing coupler; a power source; a motive devicepowered by the power source and configured to move at least a portion ofthe first or second body assembly relative to the other of the first orsecond body assembly; and a latch configured to draw the first portionof the self-aligning, self-drawing coupler to a latched positionrelative to the second portion of the self-aligning, self-drawingcoupler.

Optionally, one of the first or second body assembly includes the motivedevice.

Optionally, the first body assembly is a thigh assembly configured to beworn by a user and extends downward along a longitudinal thigh axis fromthe first portion of the self-aligning, self-drawing coupler.

Optionally, the thigh assembly includes the motive device.

Optionally, the second body assembly is a hip assembly configured to beworn by a user and extends upward and laterally away from the secondportion of the self-aligning, self-drawing coupler, and partiallycircumscribes a vertical body axis.

Optionally, the first portion of the self-aligning, self-drawing couplerincludes a tapered male portion receivable in a complimentary taperedfemale portion of the second portion of the self-aligning, self drawingcoupler.

Optionally, a length of the tapered male portion is longer than a widestwidth portion.

Optionally, the tapered male portion includes a taper angle of between 1and 10 degrees.

Optionally, the latch includes a manually operable lever.

Optionally, the first portion of the self-aligning, self-drawing couplerincludes a male portion receivable in a complimentary female portion ofthe second portion of the self-aligning, self drawing coupler, one ofthe male or female portions including a friction-reducing surface.

Optionally, the friction-reducing surface is a Teflon coating.

Optionally, the hip assembly extends laterally away from the secondportion of the self-aligning, self-drawing coupler, and includes asecond portion of a second self-aligning, self-drawing coupler.

Optionally, the wearable robotic device includes a second thigh assemblyfor attachment of a second thigh of the user and including a firstportion of a second self-aligning, self-drawing coupler.

Optionally, the thigh assembly is rotatable with respect to the hipassembly when the thigh assembly is coupled to the hip assembly by theself-aligning, self-drawing coupler.

Optionally, the second portion of the self-aligning, self-drawingcoupler includes a linkage device configured to transmit motion from aninput lever to a latch element.

Optionally, the linkage device includes an input link, a floating link,an output link, and a ground link.

Optionally, the linkage device includes a lever as the input link.

Optionally, the linkage device includes a resilient latch elementcoupled at a first end to the output link.

Optionally, the resilient latch element has a second end slidablycaptured in a guideway for controlling motion of the latch elementduring operation.

Optionally, the guideway includes a generally straight draw portionaligned with the female portion of the coupler, and an engagementportion extending laterally away from the draw portion for guiding thelatch element into and out of engagement with a corresponding latchelement of the second portion of the coupler.

Optionally, the resilient latch element provides a biasing force in thelinkage mechanism for locking the linkage mechanism in an over-centerconfiguration.

Optionally, the over-center position is a locked open position.

Optionally, the over-center position is a locked closed position.

According to another aspect, a removable, self-contained, ovularactuator cassette receivable in a receptacle of a wearable roboticdevice includes: a first circular portion housing a motive device; asecond circular portion longitudinally offset and longitudinallyoverlapping the first circular portion and housing a first portion of adrivetrain operatively coupled to and driven by the motive device; athird circular portion longitudinally offset from the first and secondcircular portions and longitudinally overlapping the second circularportion and housing a second portion of the drivetrain; an ovularhousing supporting the motive device and drivetrain; and an outputprotruding from and rotatable with respect to the housing and driven bythe drivetrain.

Optionally, the housing includes a top plate on which the motive deviceis mounted, the drive shaft of the motive device protruding through thetop plate.

Optionally, the housing includes a bottom plate.

Optionally, the drive train is sandwiched between the top plate and thebottom plate.

Optionally, the motive device is mounted outside the top and bottomplates.

Optionally, a maximum depth of the cassette measured along a rotationalaxis of the motive device is less than a maximum width and a maximumlength, the maximum width and maximum length being measured orthogonalto the depth and to each other.

Optionally, all rotational axes of the drivetrain are parallel to therotational axis of the motive device.

Optionally, long sides of the ovular housing are straight and parallelwith each other and tangentially terminate at curved end surfaces of theovular housing.

Optionally, the cassette includes an output opening in the housingthrough which the output protrudes and slide covers disposed in theoutput opening and movable with the output to cover portions of theoutput opening not occupied by the output.

Optionally, the output includes a first portion of a coupler connectableto a complimentary portion of the coupler.

According to another aspect, a wearable robotic device includes aremovable, self-contained actuator cassette including a power connectorand a driven output; and an exoskeletal assembly including a receptaclefor receiving and retaining the removable, self-contained actuatorcassette.

Optionally, the driven output includes a first portion of a couplerconnectable to a complimentary portion of the coupler.

Optionally, the removable, self-contained actuator cassette includes: afirst circular portion housing a motive device; a second circularportion longitudinally offset and longitudinally overlapping the firstcircular portion and housing a first portion of a drivetrain operativelycoupled to and driven by the motive device; a third circular portionlongitudinally offset from the first and second circular portions andlongitudinally overlapping the second circular portion and housing asecond portion of the drivetrain; an ovular housing supporting themotive device and drivetrain; and wherein the output protrudes from andis rotatable with respect to the housing and driven by the drivetrain.

Optionally, the housing includes a top plate on which the motive deviceis mounted, the drive shaft of the motive device protruding through thetop plate.

Optionally, the housing includes a bottom plate.

Optionally, the drive train is sandwiched between the top plate and thebottom plate.

Optionally, the motive device is mounted outside the top and bottomplates.

Optionally, a maximum depth of the cassette measured along a rotationalaxis of the motive device is less than a maximum width and a maximumlength, the maximum width and maximum length being measured orthogonalto the depth and to each other.

Optionally, all rotational axes of the drivetrain are parallel to therotational axis of the motive device.

Optionally, long sides of the ovular housing are straight and parallelwith each other and tangentially terminate at curved end surfaces of theovular housing.

Optionally, an exemplary wearable robotic device includes an outputopening in the housing through which the output protrudes and slidecovers disposed in the output opening and movable with the output tocover portions of the output opening not occupied by the output.

Optionally, the output includes a first portion of a coupler connectableto a complimentary portion of the coupler.

According to another aspect, a wearable robotic device includes: a firstbody assembly for attachment to a first portion of a user's body; asecond body assembly for attachment to a second portion of the user'sbody; an actuator having first and second actuator portions respectivelyconnected to the first and second body assemblies and configured to movethe first and second body assembly relative each other; wherein thefirst body assembly includes an attachment device for attaching to thefirst portion of the user's body, the attachment device including atensioning system for retention of the first body assembly to the firstportion of the user's body, the tensioning system including atensionable member and a tensioning member.

Optionally, the tensioning member includes a ratchet.

Optionally, the tensioning member includes a cable reel and thetensionable member includes a cable acted upon by the cable reel totension the cable.

Optionally, the attachment device includes a strap releasably coupled ata first end to a first strap anchor of the one body assembly.

Optionally, the strap is releasably coupled at a second end to a secondstrap anchor of the one body assembly.

Optionally, the attachment point of the strap to the strap anchor isadjustable.

Optionally, the strap is an adjustable length strap.

Optionally, the attachment device is removably coupled to the first bodyassembly at one end of the attachment device by a buckle.

Optionally, the buckle is rotatable with respect to the first bodyassembly in two orthogonal directions.

According to another aspect, a wearable robotic device includes a firstbody assembly for attachment to a first portion of a user's body; asecond body assembly for attachment to a second portion of the user'sbody; an actuator having first and second actuator portions respectivelyconnected to the first and second body assemblies and configured to movethe first and second body assembly relative each other; an attachmentdevice for attaching to the first portion of the user's body, theattachment device including a tensioning system for retention of thefirst body assembly to the first portion of the user's body, including acoarse adjuster and a separate fine adjuster.

Optionally, the fine adjuster includes a tensioning member and atensionable member.

Optionally, the tensioning member includes a ratchet.

Optionally, the tensioning member includes a cable reel and thetensionable member includes a cable acted upon by the cable reel totension the cable.

Optionally, the tensioning system includes a strap releasably coupled ata first end to a first strap anchor of the one body assembly.

Optionally, the strap is releasably coupled at a second end to a secondstrap anchor of the one body assembly.

Optionally, the attachment point of the strap to the strap anchor isadjustable.

Optionally, the strap is an adjustable length strap.

Optionally, the attachment device is removably coupled to the first bodyassembly at one end of the attachment device by a buckle.

Optionally, the buckle is rotatable with respect to the first bodyassembly in two orthogonal directions.

According to another aspect, an ankle-foot orthosis securable to auser's leg for controlling ankle movement includes a plantar element ofrigid, thin-sheeted material; a leg element having a lower portion madeof rigid thin-sheeted material rigidly connected to and extendingupwardly from the plantar element and an upper portion having aretention system to secure said upper portion to a leg; a first portionof a coupler for coupling the ankle-foot orthosis to a wearable roboticdevice.

Optionally, the lower portion of the leg element and the plantar elementare adjustably coupled to the upper portion and wherein a distancebetween the first portion of the coupler and the plantar element isadjustable.

Optionally, the distance between the first portion of the coupler andthe plantar element is infinitely adjustable between minimum and maximumdistances

Optionally, the first portion of the coupler extends upward from the legelement.

Optionally, the lower portion of the leg element is lockable withrespect to the upper portion of the leg element by means of a cam lock.

Optionally, the cam lock is manually operable.

According to another aspect, a wearable robotic device includes a thighassembly having a thigh retention system to secure the thigh assembly toa user's thigh; a lower leg assembly rotatably coupled to the thighassembly at a hinge including: a lower leg retention system to securethe thigh assembly to a user's lower leg, a lower leg housing, a plantarelement of rigid material, and a leg element made of rigid materialhaving a lower portion rigidly connected to and extending upwardly fromthe plantar element. The lower portion of the leg element and theplantar element are adjustably coupled to the lower leg housing andwherein a distance between the hinge and the plantar element isadjustable.

Optionally, the plantar element is made of a thin-sheeted material.

Optionally, the leg element is made of a thin-sheeted material.

Optionally, the thigh assembly and lower leg assembly are coupled by aquick-connect coupler.

Optionally, the quick connect coupler comprises the first and secondportions of the self-aligning, self-drawing coupler of any precedingclaim.

Optionally, the distance between the first portion of the coupler andthe plantar element is infinitely adjustable between minimum and maximumdistances.

Optionally, the first portion of the coupler extends upward from the legelement.

Optionally, the lower portion of the leg element is lockable withrespect to the upper portion of the leg element by means of a cam lock.

Optionally, the cam lock is manually operable.

According to another aspect, a wearable robotic device includes: a firstbody assembly attachable to a portion of a user's body; and a hipassembly attachable to a hip region of a user's body and coupled to thefirst body assembly and rotatable with respect to the first bodyassembly via a motive device housed in at least one of the first bodyassembly or the hip assembly, the hip assembly partially circumscribes avertical body axis and includes a rigid housing and a removableattachment device attachable to the hip region of a user's body andremovable from the rigid housing by operation of a removal mechanism,the hip assembly further includes a battery receptacle for receiving abattery, the battery receptacle being associated with the removalmechanism and the removal mechanism being positioned such that access tothe removal mechanism is precluded when the battery is installed in thebattery receptacle.

Optionally, the battery receptacle further includes electrical contactsfor mating with corresponding electrical contacts of the battery.

Optionally, the removal mechanism is manually operable.

Optionally, the removal mechanism includes a quick-release hinge pin.

Optionally, the removal mechanism includes a central guide cylinderhousing a spring longitudinally outwardly biasing first and secondfinger-operated pins slidably disposed on opposite longitudinal sides ofthe guide cylinder.

According to another aspect, a wearable robotic device includes a firstbody assembly attachable to a portion of a user's body; and a hipassembly attachable to a hip region of a user's body and coupled to thefirst body assembly and rotatable with respect to the first bodyassembly via a motive device housed in at least one of the first bodyassembly or the hip assembly, the hip assembly partially circumscribes avertical body axis and includes a rigid housing and a removableattachment device attachable to the hip region of a user's body andremovable from the rigid housing by operation of a manually operableremoval mechanism.

Optionally, the hip assembly further includes a battery receptacle forreceiving a battery.

Optionally, the battery receptacle is associated with the removalmechanism, the removal mechanism being positioned such that access tothe removal mechanism is precluded when the battery is installed in thebattery receptacle.

Optionally, the battery receptacle further includes electrical contactsfor mating with corresponding electrical contacts of the battery.

Optionally, the removal mechanism includes a quick-release hinge pin.

Optionally, the removal mechanism includes a central guide cylinderhousing a spring longitudinally outwardly biasing first and secondfinger-operated pins slidably disposed on opposite longitudinal sides ofthe guide cylinder.

Optionally, the removable attachment device includes a hooked hingeportion with an inner hook surface and an outer hook surface partiallycircumscribing a rotational axis of the attachment device, wherein therigid housing includes a hinge pin, and wherein the inner surface of thehooked hinge portion engages with the hinge pin and the removableattachment device rotates around the hinge pin when attached to therigid housing.

Optionally, the rigid housing includes a radially inward facing hingeguide surface radially offset from and partially circumscribing thehinge pin, and the outer hook surface engages the hinge guide surfacesuch that the hooked hinge portion is sandwiched between the hinge pinand the hinge guide surface when the removable attachment device isattached to the rigid housing.

Optionally, the rigid housing includes a detachment pocket into whichthe hooked hinge portion may be slid to disengage the hooked hingeportion from the hinge pin to detach the removable attachment devicefrom the rigid housing.

The foregoing and other features of the invention are hereinafterdescribed in greater detail with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a wearable robotic device being worn by a user;

FIG. 2 shows a perspective view of an exemplary wearable robotic devicein a standing position;

FIG. 3 shows a perspective view of the exemplary wearable robotic devicein a seated position;

FIG. 4 shows a front view of the exemplary wearable robotic device in astanding position;

FIG. 5 shows a left view of the exemplary wearable robotic device in astanding position;

FIG. 6 shows a back view of the exemplary wearable robotic device in astanding position;

FIG. 7 shows a broken detail view of a portion of an exemplary wearablerobotic device having a self-aligning, self-drawing coupler at the hipjoint;

FIG. 8 shows a simplified view of the linkage mechanism of theself-aligning, self-drawing coupler;

FIG. 9 shows a broken detail view of a portion of the exemplary wearablerobotic device having a self-aligning, self-drawing coupler at the hipjoint with the coupler latch mechanism in a locked open position;

FIG. 10 shows a broken detail view of a portion of the exemplarywearable robotic device having a self-aligning, self-drawing coupler atthe hip joint with the coupler latch mechanism in a closing position;

FIG. 11 shows a broken detail view of a portion of the exemplarywearable robotic device having a self-aligning, self-drawing coupler atthe hip joint with the coupler latch mechanism in a locked closeposition;

FIG. 12 shows a detail view of the self-aligning, self-drawing couplerat the hip joint with the coupler latch mechanism in a closing position;

FIG. 13 shows a detail view of the self-aligning, self-drawing couplerat the hip joint with the coupler latch mechanism in an openingposition;

FIG. 14 shows a perspective view of an exemplary thigh assembly havingtwo exemplary actuator cassettes installed therein;

FIG. 15 shows a front exploded view of the exemplary thigh assemblyhaving two exemplary actuator cassettes installed therein;

FIG. 16 shows a perspective exploded view of the exemplary thighassembly having two exemplary actuator cassettes installed therein;

FIG. 17 shows a top view of an exemplary actuator cassette;

FIG. 18 shows a bottom view of an exemplary actuator cassette;

FIG. 19 shows a perspective view of an exemplary actuator cassette;

FIG. 20 shows a cross-sectional view of an exemplary actuator cassettetaken along the longitudinal direction;

FIG. 21 shows an exemplary attachment device for use in an exemplary hipassembly having a retention system with a tensionable member and atensioning member;

FIG. 22 shows an exemplary attachment device for use in an exemplarylower leg assembly having a retention system with a tensionable memberand a tensioning member;

FIG. 23 shows a perspective view of an exemplary buckle for use in anexemplary attachment device;

FIG. 24 shows a side view of the exemplary buckle for use in anexemplary attachment device;

FIG. 25 shows an exemplary button and post for use in an exemplary clipof an exemplary attachment device;

FIG. 26 shows an exemplary clip without an attached button;

FIG. 27 shows another view of the exemplary clip without an attachedbutton;

FIG. 28 shows an exemplary attachment device for use in an exemplary hipassembly having a retention system with a tensionable member and atensioning member;

FIG. 29 shows an exemplary lower leg assembly having an exemplaryintegrated ankle-foot orthotic;

FIG. 30 shows another view or the exemplary lower leg assembly having anexemplary integrated adjustable ankle-foot orthotic with the orthoticretracted;

FIG. 31 shows another view of the exemplary lower leg assembly having anexemplary integrated adjustable ankle-foot orthotic with the orthoticpartially extended;

FIG. 32 shows a portion of an exemplary lower-leg assembly having aquick connect coupler at the top end and a cam-lock adjuster at a lowerend in a locked position for use with an exemplary ankle-foot orthotic;

FIG. 33 shows a portion of an exemplary lower-leg assembly having aquick connect coupler at the top end and a cam-lock adjuster at a lowerend in an unlocked position for use with an exemplary ankle-footorthotic;

FIG. 34 shows an exemplary hip assembly with a removable hip wing;

FIG. 35 shows a partial view of the hip assembly with the hip wingremoved;

FIG. 36 shows a partial view of the hip assembly with a portion of thehousing removed to show the interior of the hip assembly;

FIG. 37 shows a partial view of the hip assembly with a portion of thehousing removed and the guide cylinder invisible to show the spring ofthe removal mechanism;

FIG. 38 shows a rear view of the exemplary hip assembly with the batteryinstalled in the batter receptacle;

FIG. 39 shows a rear view of the exemplary hip assembly with the batterynot installed in the batter receptacle, revealing the removal mechanismof one of the hip wings;

FIG. 40 shows a partial view of the hip assembly with another exemplaryattachment mechanism between the hip wing and the rigid housing of thehip assembly;

FIG. 41 shows a sectioned view of the hip assembly with the hip wingdisconnected from the hinge pin of the rigid housing;

FIG. 42 shows another sectioned view of the hip assembly with the hipwing engaged with the hinge pin;

FIG. 43 shows another sectioned view of the hip assembly with the hipwing engaged with the hinge pin and with a guide surface of the rigidhousing;

FIG. 44 shows a permanently installed battery with the back coverremoved from the hip assembly;

FIG. 45 shows an exemplary hip assembly with a permanently installedbattery; and

FIG. 46 shows an exemplary hip assembly with a battery charging portlocated under the hip assembly.

DETAILED DESCRIPTION

Although the various embodiments will be discussed at times with respectto orthoses for providing mobility assistance for users with paraplegia,the various embodiments are not limited in this regard. The variousembodiments are equally application to other applications. For example,these can include mobility assistance for users with other conditionsother than paraplegia, rehabilitation and mobility assistance forstroke-impaired users, and mobility assistance for users withneuromuscular disabilities that impair legged mobility, to name a few,including human and non-human users. Further, embodiments may be appliedto other wearable robotic devices such as strength-enhancingexoskeletons for use in military, construction, or other applications.Thus, the various embodiments can be applied to any applications inwhich mobility assistance or enhancement is needed, either permanentlyor temporarily.

Further, although the various embodiments will be generally describedwith respect to the exemplary orthosis described below, the variousembodiments are not limited to this particular configuration. Thevarious embodiments can be embodied in or used with any type ofexoskeleton system, such as the orthosis described below and furtherillustrated in design application Ser. No. 29/486,534, the entiredisclosure of which is hereby incorporated herein by reference herein,or the orthosis described in International Publication Number WO2012/044621, the entire disclosure of which is hereby incorporated byreference herein.

The terms “exoskeleton system,” “exoskeleton,” and “wearable roboticdevice,” as used herein, refer to any type of device that can be worn orotherwise attached to a user, where the device is configured to provideenergy for motion and or support of the one or more portions of theuser.

As show in FIG. 1, a wearable robotic device 10 can be worn by a user.To attach the device to the user, the device 10 can include attachmentdevices 11 for attachment of the device to the user via belts, loops,straps, or the like. Further, for comfort of the user, the device 10 caninclude padding 12 disposed along any surface likely to come intocontact with the user. The device 10 can be used with a stability aid13, such as crutches, a walker, or the like.

An exemplary wearable robotic device is illustrated as a powered lowerlimb orthosis 100 in FIGS. 2-6. Specifically, the orthosis 100 shown inFIGS. 2-6 incorporates four motive devices (for example, electricmotors), which impose sagittal plane torques at each hip joint 102R,102L and knee joint 104R, 104L. FIG. 1 shows the orthosis in a standingposition while FIG. 3 shows the orthosis 100 in a seated position.

As seen in the figures, the orthosis contains five assemblies ormodules, although one or more of these modules may be omitted andfurther modules may be added (for example, arm modules), which are: twolower leg assemblies (modules) 106R and 106L, two thigh assemblies 108Rand 108L, and one hip assembly 110. Each thigh assembly 108R and 108Lincludes a thigh assembly housing 109R and 109L, respectively, and link,connector, or coupler 112R and 112L, respectively, extending from eachof the knee joints 104R and 104L and configured for moving in accordancewith the operation of the knee joints 104R and 104L to provide sagittalplane torque at the knee joints 104R and 104L.

The connectors 112R and 112L may be further configured for releasablymechanically coupling each of thigh assembly 108R and 108L to respectiveones of the lower leg assemblies 106R and 106L. Further, each thighassembly 108R and 108L also includes a link, connector, or coupler 114Rand 114L, respectively, extending from each of the hip joints 102R and102L and moving in accordance with the operation of the hip joints 102Rand 102L to provide sagittal plane torque at the knee joints 104R and104L. The connectors 114R and 114L may be further configured forreleasably mechanically coupling each of thigh assemblies 108R and 108Lto the hip assembly 110.

In some embodiments, the various components of device 100 can bedimensioned for the user. However, in other embodiments, the componentscan be configured to accommodate a variety of users. For example, insome embodiments, one or more extension elements can be disposed betweenthe lower leg assemblies 106R and 106L and the thigh assemblies 108R and108L to accommodate users with longer limbs. In other configurations,the lengths of the two lower leg assemblies 106R and 106L, two thighassemblies 108R and 108L, and one hip assembly 110 can be adjustable.That is, thigh assembly housings 109R, 109L, the lower leg assemblyhousings 107R and 107L for the lower leg assemblies 106R, 106L,respectively, and the hip assembly housing 113 for the hip assembly 110can be configured to allow the user or prosthestist to adjust the lengthof these components in the field. For example, these components canconsist of slidable or movable sections that can be held in one or morepositions using screws, clips, or any other types of fasteners. In viewof the foregoing, the two lower leg assemblies 106R and 106L, two thighassemblies 108R and 108L, and one hip assembly 110 can form a modularsystem allowing for one or more of the components of the orthosis 100 tobe selectively replaced and for allowing an orthosis to be created for auser without requiring customized components. Such modularity can alsogreatly facilitate the procedure for donning and doffing the device.

In orthosis 100, each thigh assembly housing 109R, 109L may includesubstantially all the components for operating corresponding ones of theknee joints 104R, 104L and the hip joints 102R, 102L. In particular,each of thigh assembly housings 109R, 109L may include two motivedevices (e.g., electric motors) which are used to drive the hip and kneearticulations. However, the various embodiments are not limited in thisregard and some components can be located in the hip assembly 110 and/orthe lower leg assemblies 106R, 106L.

For example, a battery 111 for providing power to the orthosis can belocated within hip assembly housing 113 and connectors 114R and 114L canalso provide means for connecting the battery 111 to any componentswithin either of thigh assemblies 108R and 108L. For example, theconnectors 114R and 114L can include wires, contacts, or any other typesof electrical elements for electrically connecting battery 111 toelectrically powered components in thigh assemblies 108R and 108L. Inthe various embodiments, the placement of battery 111 is not limited tobeing within hip assembly housing 113. Rather, the battery can be one ormore batteries located within any of the assemblies of orthosis 100.

Joint Coupler

Wearable robotic devices may be especially difficult to don and doffbecause of the weight of the device, and/or due to physical limitationsof users due to some medical condition. In particular, it may bedifficult to connect thigh assemblies to a hip assembly because one ormore of these assemblies may be attached to the user's body already, andcoupling may require both thigh assemblies to be coupled at the sametime. Therefore, self-aligning and self-drawing couplers may easedonning and doffing of exemplary wearable robotic devices.

An exemplary coupler incorporates a tapered joint connection with atapered top portion that interfaces with a mating tapered receptacle totightly secure the portions in place. Embodiments of this mechanicalconnection could also include an electrical interconnect 195 for powerand/or other communication; these may include redundant contacts.

Referring specifically to FIGS. 7-13, shown is an exemplaryself-aligning, self-drawing coupler for use in a wearable roboticdevice. In particular, FIG. 7 shows a portion of the hip assembly 300broken away in order to show the interior workings of the coupler.

A thigh assembly 200 for attachment to a thigh of a user includes afirst portion 154 of the self-aligning, self-drawing coupler 150, and ahip assembly 300 for attachment to a hip region of the user has a secondportion or receptacle 156 of the self-aligning, self-drawing coupler150. Although illustrated as a coupler between a thigh and a hipassembly, such coupler may be used at any appropriate connection pointof a wearable robotic device.

The coupler 150 may include a latch 152 configured to draw the firstportion 154 of the self-aligning, self-drawing coupler to a latchedposition relative to the second portion 156 of the self-aligning,self-drawing coupler.

The first portion 154 of the self-aligning, self-drawing couplerincludes a tapered male portion 158 receivable in a complimentarytapered female portion 160 of the second portion of the self-aligning,self-drawing coupler. These complimentary tapered portions create aself-aligning feature that assists a user when donning a wearablerobotic device. For example, as long as the tapered positions arebrought into general alignment, the shape of the pieces will cause thepieces to self-align when drawn together.

The length of both the tapered male portion and tapered female portionis preferably longer than a widest width portion. Further, the taper maybe in both a width and a depth direction along the length of theportions. Preferably the taper includes a taper angle of betweenapproximately 1 and 10 degrees. One embodiment may include a frictionreducing surface, such as Teflon, on at least a portion of theinterfacing surface between the male and female portions.

As shown in simplified form in FIG. 8, an exemplary coupler 150 mayinclude a four bar linkage including an input link 162, a floating link168, an output link 170, and a ground link 172 to aid in connecting thetwo separate components of a wearable robotic device. It may include amanually operable (i.e. operable without tools) lever 163 as the inputlink 162 with a cantilever portion 164 connecting to the floating link168.

At the revolute link 166 between the floating link 168 and the outputlink 170, a sliding latch element 152 is attached at a first end 174.The latch element 152 may be resilient. The other end 176 of the slidinglatch element may be restricted to sliding in a guideway or channel 178for controlling motion of the latch element during operation.

The guideway 178 may include a generally straight draw portion 180aligned with the female portion of the coupler, and an engagementportion 182 extending laterally away from the draw portion for guidingthe latch element into and out of engagement with a corresponding latchelement 190 of the second portion 154 of the coupler.

The guideway the sliding latch element is contained to be within allowsthe sliding latch element to move in either direction based on theposition and direction of the input lever. This movement allows thelatch mechanism to draw the connecting link into the receptacle or toeject the link from the receptacle, as shown in FIGS. 12 and 13,respectively. Preferably, the sliding latch element rides in a channelthat is curved to push the sliding latch element out of the way in thefully open position allowing for unobstructed removal or insertion.

The resilient latch element 152 may provide a biasing force in thelinkage mechanism for locking the linkage mechanism in an over-centerconfiguration. The over-center position may be either in a locked openposition as illustrated in FIG. 9, or a locked close position asillustrated in FIG. 11, although, preferably, it is both. The resilientlatch, when in an over-center, locked close position, holds the inputlever closed with the spring load and takes up tolerance in the hiplink. The resilient latch, when in an over-center, locked closeposition, can secure the lever in an open position and secure thesliding latch element in a position that prevents the sliding latchelement from blocking the connecting link during insertion. When theconnecting link is inserted, it will catch the sliding latch element152. With the connecting link partially inserted, the input lever of thefour bar linkage can be used to fully insert the connecting link,creating a self-drawing feature.

The male portion of the coupler may include a notch 190 that the slidinglatch element can interface with and pull or push the connecting link.This controlled action provides a consistent connection of the link.

In one embodiment the sliding latch element and notch can be used to“key” the connecting link to prevent improper insertion. This alsoprevents incorrect electrical connections.

As noted above, the connectors 112R, 112L, 114R, and 114L, and/or theself-aligning, self-drawing coupler 150 can be configured to providemechanical and electrical connections. In the event that an electricalconnection is needed between the thigh assembly 108R and lower legassembly 106R, wires can be routed through the interior of connector112R to electrical contacts. A corresponding set of electrical contacts190 would also be provided in the interior of the female portion.Accordingly, when a male portion is locked into the female portion, theelectrical contacts are placed in contact with the correspondingelectrical contacts within the female portion. A similar configurationcan be provided for links 112L, 114R, and 114L. It is noted though thatthe various embodiments self-aligning, self-drawing coupler may be usedon any suitable device and may, in particular, be used with any otherexemplary devices disclosed herein.

Actuator Cassette

In the various embodiments, in order to maintain a low weight fororthosis and a reduced profile for the various components, asubstantially planar drive system is used to drive the hip and kneearticulations. For example, each motor can respectively drive anassociated joint through a speed-reduction transmission using anarrangement of sprocket gears and chains substantially parallel to theplane of sagittal motion.

The powered joints may be implemented by disposing a joint sprocket gear504 at one end of thigh assembly housing 109R parallel to the sagittalplane and configuring the joint sprocket gear 504 to rotate parallel tothe sagittal plane. To provide the sagittal plane torque for knee joint102R, the connector 112R can extend from the joint sprocket gear 504 andbe mechanically connected, so that rotation of the joint sprocket gear504 results in application of torque to the lower leg assembly 106. Aslot or receiving element can be provided for the connector 112R to linkthe thigh assembly 108R and lower leg assembly 106R. The receivingelement and the connector 112R can be configured such that the connectorcan removably connect the thigh assembly 108R and lower leg assembly106R. In the various embodiments, clips, screws, or any other types offastener arrangements can be used to provide a permanent or a removableconnection. In some embodiments, quick connect or “snap-in” devices canbe provided for providing the connection. That is, these quick connectdevices allow connections to be made without the need of tools. Thesetypes of quick connect devices can not only be used for mechanicallycoupling, but for electrical coupling. In some embodiments, a singlequick connect device can be used to provide both electrical andmechanical coupling. However, the various embodiments are not limited inthis regard and separate quick connect devices can be provided for theelectrical and mechanical coupling. It is worth noting that with quickdisconnect devices at each joint, the orthosis can be easily separatedinto three or five modular components—right thigh, left thigh, rightlower leg, left lower leg, and hip assemblies—for ease of donning anddoffing and also for increased portability.

The knee joint 104R may be actuated via operation of a motor 502, asdiscussed above. The motor 502 can be an electric motor that drives theknee joint 104R (i.e., joint sprocket gear 504) using a two-stage chaindrive transmission. For example, as shown in FIG. 20, a first stage canconsist of the motor 502 driving, either directly or via a first chain,a first drive sprocket gear 514. The first drive sprocket gear 514 ismechanically coupled to a second drive sprocket gear 516 so that theyrotate together about the same axis based on the power applied by motor502 to first drive sprocket gear 514. The second drive sprocket gear 516can be arranged so that it is disposed in the same plane as the jointgear 504. Thus, a second chain can then be used to drive joint sprocketgear 504 using the second drive sprocket gear 516 and actuate the kneejoint 104R. The gear ratios for the various components described abovecan be selected based on a needed amount of torque for a joint, powerconstraints, and space constraints.

Each stage of the chain drive transmission can include tensioners, whichcan remove slack from a chain and mitigate shock loading. Suchtensioners can be adjustable or spring loaded.

In addition, a brake 570 can be provided for motor 502. For example, asolenoid brake may be provided which engages a brake pad against therotor 524 of the motor 502 in one state, and disengages the brake pad inanother state. However, the various embodiments are not limited to thisparticular brake arrangement and any other methods for providing a brakefor motor 502 can be used without limitation.

The configuration illustrated in FIG. 20 has been discussed above withrespect to an arrangement of sprocket gears and chains. However, thevarious embodiments are not limited in this regard. That is, any otherarrangement of gears, with or without chains, and providing a reducedprofile can be used. Further, the various embodiments disclosed hereinare not limited to an arrangement of gears and/or chains. For example,in some configurations, a belt and pulley arrangement could be used inplace of the chain and sprocket arrangement. Further, a friction drivearrangement can also be used. Also, any combination of the arrangementsdiscussed above can be used as well. Additionally, different joints canemploy different arrangements.

In the various embodiments, a motor for each of joints 102R, 102L, 104R,104L can be configured to provide a baseline amount of continuous torqueand a higher amount of torque for shorter periods of time. For example,in one configuration, at least 10 Nm of continuous torque and at least25 Nm of torque for shorter (i.e., 2-sec) durations are provided. Inanother example, up to 12 Nm of continuous torque and 40 Nm of torquefor shorter (i.e., 2-sec) durations. As a safety measure, both kneejoints 104R and 104L can include normally locked brakes, as discussedabove, in order to preclude knee buckling in the event of a powerfailure.

Referring now to FIGS. 14-20, consolidating the moveable parts describedabove into self-contained units, referred to herein as “cassettes,”allow for ease of maintenance and replacement because cassettes areswappable, making them easier to service or requiring less of a varietyin spare components. As used herein, “self-contained” means that thecassette includes everything necessary to operate in a fully functionalmanner if supplied with power. Thus, for example, if power is suppliedto electrical contacts of the cassette, the cassette would actuate.

In the illustrated embodiment, the motor is integrated onto a commonbaseplate along with sprockets that control the motion of a joint link.Bearings and chains, with and/or without tensioners provide smooth andefficient transfer of motion from the motor to the joint angle.Integrating the motor into the cassette allows for a thinner overallpackage configuration and provides consistent alignment among parts.Moreover, integrating the motor also creates a larger surface area totransfer and emit heat generated by the motor.

In the instance of a mobility assistance device, as in the currentinvention, these cassettes may pertain to a specific joint or set ofjoints on the device. Each may have a unique actuation unit or share anactuation unit. They may include actuators, with or without a powersource, and/or a method of transmitting movement. The illustratedembodiment includes a brushless DC motor with chains and sprockets tocreate and transmit motion, however other embodiments may utilizeelectric motors, linear actuators, piezoelectric actuators, belts, ballscrews, harmonic drive, gear drive (bevel or planetary), or anycombination thereof. One embodiment may also house electronics and/orsensors.

The self-contained unit(s) can be preassembled to aid in manufacturingthe broader device. This allows for quick servicing of the device sinceindividual cassettes can be swapped out and serviced.

Therefore, a removable, self-contained, ovular actuator cassette 500 maybe receivable in a receptacle of a wearable robotic device. The cassette500 may include a first circular portion 520 housing a motive device(e.g., an electric motor) 502. A second circular portion 522 may belongitudinally offset and longitudinally overlapping the first circularportion and may house a first portion of a drivetrain 514, 516operatively coupled to and driven by the motive device 502. A thirdcircular portion 524 may be longitudinally offset from the first andsecond circular portions and longitudinally overlapping the secondcircular portion and may house a second portion of the drivetrain 504.

These three overlapping circular portions make an ovular shape.Therefore, an ovular housing 530 may support the motive device 502 anddrivetrain 502, 514, 516. Long sides of the ovular housing are straightand parallel with each other and tangentially terminate as curved endsurfaces of the ovular housing.

An output 112R may protrude from and be rotatable with respect to thehousing and driven by the drivetrain.

The housing may include a top plate 532 on which the motive device ismounted. As shown in FIG. 20, the drive shaft of the motive device 502may protrude through the top plate 532.

The housing may also include a bottom plate 534 coupled to the top plate532. The drive train is sandwiched between and supported by the topplate 532 and the bottom plate 534. Preferably, the motive device 502 ismounted outside the top and bottom plates on a laterally offset portion536 of the top plate.

As shown in the figures, the maximum depth of the cassette measuredalong a rotational axis of the motive device is less than the maximumwidth and the maximum length of the cassette, thereby achieving a thin,flat profile.

The output 112R may protrude through an output opening 540. Slide covers542 disposed in the output opening and movable with the output 112R tocover portions of the output opening not occupied by the output may alsobe provided. Alternatively, brushed covers or other means known in theart may be used to protect the interior of the cassette fromcontamination.

As discussed above, the output 112R may be the first portion of theself-aligning, self-drawing coupler discussed above.

The cassette may be disposed in an appropriate receptacle 560 of thethigh assembly.

Retention System

A wearable robotic device often needs to be donned and doffed underdifficult circumstances, including, for example, by a user who isparalyzed. Therefore, an improved attachment system is desirable.

A body assembly, for example, a hip assembly, may include an attachmentdevice 600, 600′ for attaching to the first portion of the user's body.The attachment device may include a tensioning system 650, 650′ forretention of the first body assembly to the user's body. In preferredembodiments, the tensioning system includes both a tensionable member652, 652′ and a tensioning member 654, 654′.

As shown in FIGS. 21 and 22, a cable or lace 656, 656′ is threadedthrough a looped strap 658, 658′ and connected back onto itself.

The tensioning system preferably includes a cable reel system having acable reel 660, 660′ and a cable 656, 656′ extending from the reel, andcable guides (not shown). The reel may be a spring-loaded rotating spoolthat winds or unwinds the cable to either tension or untension thecable. Suitable devices to use for the reel are cable reel devicesavailable under the name BOA from Boa Technology, Inc. of Denver, Colo.,and described in U.S. Pat. Nos. 7,954,204 and 7,992,261, incorporated byreference in their entireties. The reel may be mounted to the substrate670, 670′, as by use of plastic rivets, and the like.

Preferably, the cable reel is a rotating spool that winds or unwinds thecable and, preferably includes a toothed housing configured forreceiving the ends of the cable, each end rotationally linked to a spoolcontained within the housing of the cable reel. A knob having aspring-loaded assembly cooperates with the housing and the spool formanually winding the cable around the spool. The knob and spring-loadedassembly cooperate to engage the spool with the housing to provide aratchet feature for winding the spool when the knob is turned in onedirection to tension the cable, and for releasing the spool to untensionthe cable. The cable may be, for example, a nylon coated, stainlesssteel cable.

The cable reel 660, 660′ may be mounted to a plastic support piece (notshown) that retains the housing with or without the need for otherretention methods, such as thread, removable brackets, adhesives, etc.

At the furthest extent, the strap does not extend beyond the plasticsupport base. The preferred embodiment utilizes the support base as alow friction surface for the strap to slide against and provides alarger surface area for the lace to distribute pressure. When the spoolretracts the lace the strap is effectively shortened as it is pulledtoward the spool at the base of the support. This shortening tightensthe strap when it is attached at one end and the support is attached atanother, completing a loop.

As shown in FIG. 22, the tail of the strap 658′ may be is attached to arigid structure of the body assembly at attachment anchor 664, 664′. Theattachment could be permanent or temporary. A preferred method would betemporary, allowing for the entire strap to be adjusted or removed. Somemethods for attachment could include threading it back on itself, hookand loop fasteners, button fasteners, or any combination of the above orother fastening method. Exemplary embodiments thread the strap 658′through a series of slots to create adequate friction that secures thestrap. This method allows the strap to be adjusted to accommodate a widerange of overall lengths.

In exemplary embodiments, the strap may be composed of or contain hookor loop material that can be used to secure the strap to the frame at anattachment anchor 664′ or to attach other accessories, such as padding.

As shown in FIG. 21, the attachment device may include a sleeve tocontain the support, lace, and strap.

Padding may be placed on the back side of the support 670. This could beadhered to the support, to the sleeve (if present) or floating in place.The padding aids further in the comfort and distribution of pressure.

As shown in FIG. 28, a mechanism for attaching the support to the framemay include a quick connect/disconnect. A preferred embodiment includesa button hole and post design, as detailed in FIGS. 23-27. On either theframe or the strap support 684 is a button 680 atop a post 682 and abuckle/clip 690 with a keyhole opening 692. Preferably, the keyholeincludes a first circular opening overlapping a second, larger circularopening, the larger circular opening disposed distal the first, smalleropening in relation to the button 680. The keyhole structure allows forthe buckle to slide over the larger diameter of the button head andslide tight around the post.

One embodiment may include both the button/post and keyhole features tobe secured to straps; when they are connected they join the two.

The present invention discloses a round post that allows the buckle torevolve. Further, the bottom portion of the button head 684, just abovethe connection to the post is slightly curved. This curvature allows theclip 690 to pivot. The degree of pivot is dependent on the height of thepost in relation to the thickness of the buckle and the curvature of thebottom of the button relative to the diameter of the post.

The button hole and post connect/disconnect method can be useindependently of the tensioning strap method to secure other strappingto a frame or another strap. This buckle and clip design can be usedindependently or combined with other strapping methods.

As disclosed above, the adjustable and removable straps allow for coarseadjustment of the attachment device, while tensioning by the cable reelallows for fine adjustment of the attachment device.

AFO System

The lower-leg assembly 106L, 106R may include an ankle foot orthotic(AFO) 700 that can be used independently or attach to a joint, such asone found on a wearable robotic device. Preferred embodiments include aquick connect/disconnect 702 between the lower-leg assembly and the restof the robotic system so that, for example, the lower leg assembly couldbe worn all day, and the rest of the wearable robotic assembly could beattached when required. This can result in much quicker and easierdonning and doffing, as a dedicated AFO would not have to be removedfrom under a shoe and replaced by an AFO integrated into a wearablerobotic device.

Further, as shown in FIGS. 30 and 31, exemplary lower-leg assembliesallow for the length to be adjusted while worn by the user or separatefrom the user. One embodiment may include markings to indicate totalassembly length or that can be used to determine said length.

The lower leg assembly 106L includes an AFO having a plantar element 720which may be of a rigid, thin-sheeted material. This plantar elementwould be placed under the sole of a user's foot, and may fit within ashoe. A leg element 722 may also be made of rigid thin-sheeted material,and may have a lower portion 724 rigidly connected to and extendingupwardly from the plantar element. The lower portion of the leg elementand the plantar element are adjustably coupled to the housing 726 of thelower-leg assembly. Although only the lateral side of the illustratedAFO provides load bearing support, other embodiments may bear support atthe front, rear, medial, or any combination thereof.

Further, exemplary embodiments may include a quick adjust mechanism 710,shown in more detail in FIGS. 32 and 33, utilizing a cam lock 712 devicemovable by way of a manually operated lever 714 that allows forinfinitely variable length between a maximum and a minimum without theuse of tools or power source.

Hip Wings

Referring now to FIGS. 34-39, a hip assembly 800 includes pivoting hipwings as part of an attachment device that attaches a portion of awearable robotic device to a user. Because these wings may be standardsizes or semi-customized or customized to the user customized to a userbased on size and/or support needed based on physical limitations of theuser, the wings may need to be removed on a regular basis in clinicalsettings. Therefore, exemplary embodiments include a quickconnect/disconnect mechanism that is manually operable (i.e. operablewithout tools).

An exemplary wearable robotic device includes a hip assembly 800attachable to a hip region of a user's body and coupled to another bodyassembly (e.g., a thigh assembly) and rotatable with respect to thefirst body assembly via a motive device housed in at least one of thefirst body assembly or the hip assembly. The hip assembly includes arigid housing 810 and a removable attachment device or hip wing 820attachable to the hip region of a user's body and removable from therigid housing by operation of a manually operable removal mechanism 830.

FIG. 35 shows a detailed view of the hip assembly with the hip wing 820removed and the removal mechanism 830 visible.

FIG. 36 shows another detailed view of the hip assembly, this time witha portion of the rigid housing 810 removed for clarity. As is evident,the removal mechanism may be a quick-release hinge pin.

The removal mechanism 830 includes a central guide cylinder 832 housinga spring 834 longitudinally outwardly biasing first and secondfinger-operated pins 836, 838 slidably disposed on opposite longitudinalsides of the guide cylinder. These pins or end caps act as hinges wheninstalled with the wings on the rigid housing. When the end caps arepinched together, compressing the spring, the pins retract into theridged frame, allowing the wings to be freely removed or inserted. Theguide cylinder prevents the spring from buckling during compression andmay reduce friction to minimize force to activate the latch to releasethe wings.

In exemplary embodiments the wing release is not exposed duringoperation. Rather, laterally extending grip portions 840, 842 mayprotrude into a battery receptacle 870. This way, the wings cannot beremoved when the battery 860 is in place because access to the removalmechanism is precluded when the battery is installed in the batteryreceptacle. Further, the battery may be shaped such that the batterycannot be connected if wings are only partially installed.

The battery receptacle further includes electrical contacts 890 formating with corresponding electrical contacts of the battery (notshown).

Turning now to FIGS. 40-46, an exemplary embodiment of the hip assemblyis shown at 900. The hip assembly 900 is substantially the same as theabove-referenced hip assembly 800, and consequently the same referencenumerals but indexed by 100 are used to denote structures correspondingto similar structures in the hip assembly. In addition, the foregoingdescription of the hip assembly 800 is equally applicable to the hipassembly 900 except as noted below. Moreover, it will be appreciatedupon reading and understanding the specification that aspects of the hipassemblies may be substituted for one another or used in conjunctionwith one another where applicable.

The hip assembly includes a rigid housing 910 and a removable attachmentdevice or hip wing 920 attachable to the hip region of a user's body andremovable from the rigid housing by operation of a manually operableremoval mechanism 930.

FIG. 41 shows a detailed sectioned view of the hip assembly with the hipwing 920 detached from the rigid housing 910 and the removal mechanism930 visible. In this case, the removal mechanism is a combination offeatures that will be described further below. It is noted that morethan one removal mechanism 930 may be included on each hip wing 920. Forexample, the depicted hip wing includes upper and lower attachmentportions 921, 923, and each of these attachment portions may include oneor more attachment points 925, 927.

The hip wing/removable attachment device 920 includes a hooked hingeportion 922 with an inner hook surface 924 and an outer hook surface926. The outer hook surface partially circumscribes a rotational axis933 of the hip wing when the hip wing is attached to the rigid housing.

The inner hook surface 924 engages with the hinge pin 932 and theremovable attachment device rotates around the hinge pin when attachedto the rigid housing. Optionally, the hinge pin 932 extends axiallythrough the rigid housing 910 and acts as a hinge pin for everyattachment point of the hip wing 920. Optionally, the inner and or outerhook surfaces 924, 926 are circular. If the hinge pin is also circular,the inner hook surface 924 may contact the hinge pin along the entireextent of the inner hook surface, or at least the portion thereof thatis also circular.

The hook portion 922 has an opening 928 into which the hinge pin 932passes when attaching and detaching the hip wing 920. This opening 928is optionally the same width as the diameter of the hinge pin 932,therefore allowing unimpeded attachment and detachment. Alternatively,the opening 928 may be larger and may taper inwardly in order to moreeasily guide and attach the hooked portion 922 onto the pin 932.Alternatively, the opening may include a portion that is narrower thanthe hinge pin so as to produce a positive detent snap-connection betweenthe hinge pin 932 and the hook portion 922 via spring-like deformationof the hook portion 922.

The rigid housing 910 includes a radially inward facing hinge guidesurface 934 radially offset from and partially circumscribing the hingepin 932. The outer hook surface 924 may engage the hinge guide surface934 such that the hooked hinge portion 922 is sandwiched between thehinge pin 932 and the hinge guide surface 934 when the hip wing isattached to the rigid housing.

The rigid housing includes a detachment pocket 935 into which the hookedhinge portion 922 may be slid to disengage the hooked hinge portion fromthe hinge pin 932 to detach the hip wing from the rigid housing 910. InFIG. 41, the hooked hinge portion 922 is in the detachment pocket 935.

Optionally, the detachment pocket includes a flat wall 936 that actswith a flat portion 929 of the outer hook surface 926 to provide apositive stop for a user when attaching the hip wing to the rigidhousing. The detachment pocket 935 is adjacent the guide surface 934 andis deep enough for the hooked hinge portion 922 to clear the hinge pin932 so as to allow complete removal of the hip wing 920 from the rigidhousing 910.

FIG. 42 shows the hip wing being slid onto the hinge pin 932 from theposition shown in FIG. 41. FIG. 43 shows the hip wing being rotated outto a “normal” or “operative” position to engage the hooked hinge portion922 with the guide surface 934 from the position shown in FIG. 42.Removal of the hip wing 920 from the rigid housing 930 may beaccomplished by the opposite order of movements shown in FIGS. 41-43. Inparticular, a method for removing the hip wing includes rotating the hipwing about the hinge pin until the hooked hinge portion 922 is alignedwith the pocket 935. This rotational movement is preferably a rotationof the hip wing inward toward the middle of the rigid housing. Thismovement disengages the hooked hinge portion 922 from the guide surface934. Once aligned, the hooked hinge portion 922 is slid into the pocket935 to disengage from the hinge pin 932. Finally, the hip wing 920 maybe removed from the rigid housing.

The foregoing manual removal method has the advantage of preventingaccidental or purposeful removal of the hip wing during use of thewearable robotic device. In particular, the body of the user wouldprevent rotation of the hip wing inwardly toward the middle of the rigidhousing, therefore, the hooked hinge portion would be prevented fromdisengaging with the guide surface and the hinge pin.

Because this manual removal method and system does not require access tothe interior of the rigid housing, exemplary embodiments may optionallyinclude an integral or permanently-installed battery, in contrast to theremovable battery described above. FIG. 44 shows such a permanentlyinstalled battery 960 in the rigid housing of the hip assembly. FIG. 45shows an exemplary hip assembly from the back side, and it is evidentthat the permanently-installed battery allows for the benefit of fewerparts in this assembly (such, as for example, no need for separatebattery contacts, a battery lock mechanism, or a battery latchmechanism. Furthermore, the back of the hip assembly is now able to befree of seems, allowing for a cleaner, sleeker look, more surface arefor branding, a more easily-cleanable product, and fewer surfacediscontinuities that could catch on clothing or other environmentalobjects.

The battery 960 may be charged via a battery port 965 which may belocated anywhere that is convenient, but is preferably mounted to anunderside of the hip assembly as shown in FIG. 46. An underside mountmay have the advantage of preventing debris from the environment (suchas, for example, dust and rain) from entering or blocking the batteryport 965.

Although the invention has been shown and described with respect to acertain embodiment or embodiments, it is obvious that equivalentalterations and modifications will occur to others skilled in the artupon the reading and understanding of this specification and the annexeddrawings. In particular regard to the various functions performed by theabove described elements (components, assemblies, devices, compositions,etc.), the terms (including a reference to a “means”) used to describesuch elements are intended to correspond, unless otherwise indicated, toany element which performs the specified function of the describedelement (i.e., that is functionally equivalent), even though notstructurally equivalent to the disclosed structure which performs thefunction in the herein illustrated exemplary embodiment or embodimentsof the invention. In addition, while a particular feature of theinvention may have been described above with respect to only one or moreof several illustrated embodiments, such feature may be combined withone or more other features of the other embodiments, as may be desiredand advantageous for any given or particular application.

What is claimed is:
 1. A wearable robotic device comprising: a thighassembly having a first attachment device to secure the thigh assemblyto a user's thigh; a lower leg assembly rotatably coupled to the thighassembly at a knee joint, the lower leg assembly including: a secondattachment device to secure the lower leg assembly to the user's lowerleg, a lower leg housing, a rigid plantar element, a rigid leg elementhaving a lower portion rigidly connected to and extending upwardly fromthe plantar element, and a cam lock device and a manually operated leverthat is coupled to the cam lock device, the cam lock device beingmovable by operation of the manually operated lever; wherein the lowerportion of the leg element and the plantar element are adjustablycoupled to the lower leg housing by the cam lock device and wherein adistance between the knee joint and the plantar element is adjustable byoperation of the lever to move the cam lock device, so that the cam lockdevice can lock the distance between the knee joint and plantar elementat any distance between minimum and maximum distances.
 2. The wearablerobotic device of claim 1, wherein the plantar element is made of athin-sheeted material that is configured to be placed under a sole of auser's foot and fit within a shoe.
 3. The wearable robotic device ofclaim 1, wherein the leg element is made of a thin-sheeted material. 4.The wearable robotic device of claim 1, wherein the thigh assembly andlower leg assembly are coupled by a quick-connect coupler.
 5. Thewearable robotic device of claim 4, wherein the quick-connect couplercomprises a first portion and a second portion that are drawn togetherduring a coupling operation, and a distance between the first portion ofthe quick-connect coupler and the plantar element is continuouslyadjustable between the minimum and maximum distances.